The latest requirement in the operation of energy machines (particularly wind and thermal power plants) is to increase efficiency, extend service life, and lengthen the intervals between necessary maintenance shutdowns. For wind power plants, this is achieved by applying a new generation of plasma coatings to the friction surfaces of bearing components, thereby reducing energy losses and improving overall efficiency.
In current research and development, sliding layers are designed as a complex system that combines a low coefficient of friction with a low wear rate, while also providing excellent mechanical properties. The most promising materials are coatings based on amorphous or diamond-like carbon (DLC), as well as nanocomposite layers with a combined metal–carbon structure. These materials are particularly attractive because they offer both excellent sliding performance (low friction) and high wear resistance, although their full potential has not yet been fully explored.
In demanding industrial applications, the performance of coatings hinges on their adhesion, which directly impacts their reliability. Exceptional adhesion is essential, even at low deposition temperatures of up to 200 °C—conditions typical for most bearing steel components.
For thermal power plants, we are developing a new generation of coatings designed to enhance the value of steam turbines by boosting both efficiency and lifespan. Standard turbine blades are among the most heavily stressed components, enduring mechanical and chemical wear caused by solid or liquid particles at operating temperatures that can reach 650 °C. As a result, turbine blades require regular inspection and, when necessary, repair or replacement.
Neglecting maintenance can, in extreme cases, compromise the entire turbine. Staton s.r.o. is developing an advanced coating to protect the surfaces of steam turbine blades in thermal power plants, enhancing their resistance to mechanical wear while also improving thermal and oxidation stability. This innovation directly extends the service life of the blades and reduces costly maintenance intervals—periods that inevitably require turbine shutdown and result in financial losses.
Coatings based on TiAlN show particular promise, offering excellent hardness along with high thermal stability, making them a strong candidate for next-generation turbine protection.
The new generation of coatings features advanced nanostructures, forming a so-called superlattice structure. This cutting-edge technology not only enhances performance but also allows the turbine blades themselves to be lighter, further improving the efficiency of steam turbines.
Coatings for Wind Turbine Bearings
- Low friction coefficient
- Reliable performance under demanding conditions, including very low or high temperatures and extreme contact pressures
- Outstanding mechanical properties with minimal wear
- Improved power plant efficiency
- Extended service life of components
- Reduced operating costs
- Environmentally friendly deposition and use
- Potential for wider use in other tribological systems, including bearings and transmission components
Coatings for Steam Turbine Blades in Thermal Power Plants
- Enhanced coating hardness
- Improved resistance of blades to mechanical wear
- Superior coating adhesion
- Greater heat and oxidation resistance
- Extended blade service life
- Longer intervals between costly turbine maintenance shutdowns
- Reduced blade weight for improved efficiency
- Increased overall steam turbine performance
- Environmentally friendly deposition and use
- Potential use in other turbine technologies, including aircraft engines
